Amarillo® Gear Company
USER MANUAL
Gearbox Service Unit
GSU110 2.0
Table of contents
1. GENERAL INFORMATION
4
1.1
Introduction .................................................................................................................................... 4
1.2
Symbols and signs used in the documentation ............................................................................. 4
1.3
Health and Safety........................................................................................................................... 5
1.3.1
Notes, warnings and cautions ..................................................................................................... 5
1.4
Intended use and limitations .......................................................................................................... 8
1.5
Functional description .................................................................................................................... 8
1.5.1
The Gearbox Service Unit ........................................................................................................... 8
1.5.2
The Gearbox Service Unit Filter element .................................................................................... 8
1.5.3
Principle of operation .................................................................................................................. 8
1.6
Filter performance .......................................................................................................................... 8
1.6.1
Filter element change based on service time – 12 months ........................................................ 8
1.6.2
Filter element change due to high pressure – 1.8 bar ................................................................ 9
1.6.3
Technical specifications ............................................................................................................ 10
2
INSTALLATION
11
2.1
General......................................................................................................................................... 11
2.2
Taking delivery of a Gearbox Service Unit................................................................................... 11
2.2.1
Unpacking ................................................................................................................................. 11
2.2.2
Inspection upon receipt ............................................................................................................. 11
2.2.3
Storage until installation ............................................................................................................ 11
2.3
Installation .................................................................................................................................... 12
2.3.1
Piping ........................................................................................................................................ 12
2.3.2
Electrical connection ................................................................................................................. 12
3
OPERATION
14
3.1
Starting the filter system............................................................................................................... 14
3.2
Normal operation and service ...................................................................................................... 14
3.2.1
Filter change based on service time – 12 months .................................................................... 14
3.2.2
Filter change due to high pressure – 1.8 bar ............................................................................ 14
3.3
Stop .............................................................................................................................................. 14
3.3.1
Replacing the filter element ...................................................................................................... 15
4
MAINTENANCE
17
4.1
Preventive Maintenance............................................................................................................... 17
4.2
Trouble Shooting .......................................................................................................................... 18
5
END OF LIFE CYCLE
20
5.1
CAUTIONS ................................................................................................................................... 20
5.2
Material content ............................................................................................................................ 20
Page 2 of 20
Rev. A 08.07-2010
List of tables and figures
Table 1.1 Technical data Gearbox Service Unit .................................................................................... 10
Fig. 1.1 Gearbox Service Unit ............................................................................................................... 10
Table 2.1 Torque overview .................................................................................................................... 12
Fig. 2.1 Wire connection for motor ........................................................................................................ 13
Fig. 3.1 Exploded view Gearbox Service Unit ....................................................................................... 16
Table 4.1 Service parts and intervals .................................................................................................... 17
Table 4.2 Trouble shooting .................................................................................................................... 18
Table 5.1 Material content ..................................................................................................................... 20
Page 3 of 20
Rev. A 08.07-2010
1. GENERAL INFORMATION
1.1
Introduction
Oil contamination causes approximately 80% of all oil system failures. Contamination takes the form of
insoluble materials such as metals, dust particles, sand and rubber, oil degradation products such as
varnish, resin and oxidation residues and water. The smallest particles, (below 5 µm), free water and
deposits from oil degradation products are often responsible for defects.
These contaminants influence equipment reliability and service life, and nearly 100% of all problems
related to contamination of oil and other fluids can be prevented.
The Gearbox Service Unit is used for oil maintenance. It is generally used as an off-line filtration system in continuous operation.
Applying a Gearbox Service Unit to your system will give you the benefit of increased uptime of production machinery and extended service life for system components, by effectively reducing oil contamination from:
 Insoluble particles
 Oil degradation products and oxidation by-products
 Water
1.2
Symbols and signs used in the documentation
Within this manual, safety instructions are marked with safety symbols. This general hazard symbol
below highlights information which non-compliance with, could cause a risk to personal safety.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury. It may also be used to alert against unsafe practices.
NOTE!
Point out generally important information.
Page 4 of 20
Rev. A 08.07-2010
1.3
Health and Safety
1.3.1
Notes, warnings and cautions
NOTE!
Before installing the Gearbox Service Unit, ensure personnel transporting and installing it are qualified and have read and fully understood this instruction manual.
NOTE!
Installation of the electrical power supply must only be carried out by qualified personnel. Relevant requirements from national standards concerning electrical installation
must be applied.
NOTE!
Do NOT attempt to repair or disassemble the Gearbox Service Unit or any of its components within the warranty period, unless special permission has been granted in writing
by the supplier (with the exception of dismantling for replacement of filter elements).
Failure to seek the said permission will cause the warranty on the said parts to be void.
NOTE!
Use only original spare parts.
NOTE!
Do NOT clean the Gearbox Service Unit by using a pressure washer. Use a general purpose cleaner only.
DANGER
EXPLOSIVE ATMOSPHERES
 The Gearbox Service Unit must not be used in ATEX characterized areas.
DANGER
COMPRESSED AIR OR GASES
Pressurising any part of the Gearbox Service Unit with compressed air or other compressed gases may lead to explosion, causing death or serious injury.
 Leak testing of the Gearbox Service Unit must only be carried of with atmospheric
air at a pressure of less than 0.5 bar.
WARNING
HAZARDOUS VOLTAGE
Contact may cause electric shock or burn.
 Turn off and lock primary and control circuit power disconnecting switch before
installing or servicing.
 Keep all panels and covers securely in place.
Page 5 of 20
Rev. A 08.07-2010
WARNING
ELECTRICAL SHOCK
Different electrical potential between adjacent machinery may cause electrical shock.
 The Gearbox Service Unit must be supplied from the same electrical source as any
machinery connected or adjacent machinery must be inter-connected by an equipotential bonding wire.
WARNING
SLIPPERY FLOOR
Oil spillage may cause injury.
 Always clean up spilled oil and repair leaks.
WARNING
HOT SURFACES
Piping and filter housing may contain hot oil.
Contact may cause burns.
 Allow to cool before servicing.
WARNING
TRANSPORTATION
 Use only approved lifting gear.
WARNING
SKIN CONTACT WITH OIL
Skin contact with oil can cause allergic reactions.
 Wear suitable gloves, chemical resistant disposable clothing and goggles when
servicing or repairing.
CAUTION
HIGH AMBIENT TEMPERATURES
High ambient temperature may cause malfunction of the electrical components.
 Do NOT expose the Gearbox Service Unit to ambient temperatures higher than
stated in this instruction manual.
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Rev. A 08.07-2010
CAUTION
HIGH FLUID TEMPERATURES
Excessive fluid temperatures may decompose sealing and hose components.
 Do NOT expose the Gearbox Service Unit to fluid temperatures exceeding design
temperature as stated in this instruction manual.
CAUTION
UNINTENDED OPERATION OF SHUT-OFF VALVES
Unintended operation of manually operated shut–off valves may disturb the safe and
correct functioning of the Gearbox Service Unit or the machinery connected.
 Manually operated shut-off valves must be secured against unintended activation
during operation.
CAUTION
UNINTENDED DRAINAGE OF MACHINERY MAIN SYSTEM OIL RESERVOIR
Erroneous operation, component failure or leaks may drain the main system oil tank.
 User must install necessary equipment or apply procedures to monitor oil level in
the main system oil tank.
NOTE!
Never use tapered thread when connecting the Gearbox Service Unit, due to risk of
cracks in the material.
NOTE!
Never use fittings or pipes made of copper, copper alloys or with a galvanized surface
due to risk of accelerating oil degradation.
NOTE!
All types of oil are potential threats to the environment and as such they must NOT be
drained into ordinary sewers or dumped. Always check that all oil-carrying components
are sealed and do not leak before operating the Gearbox Service Unit.
NOTE!
Service life can be shortened if exposed to severe vibrations.
Install vibration dampers if relevant.
NOTE!
On completion of installation or service, all safety and protective equipment must be reinstalled and made operative again prior to restarting the machine. Never disable, modify, or by-pass any safety locks.
Page 7 of 20
Rev. A 08.07-2010
1.4

Intended use and limitations
The Gearbox Service Unit must NOT be used for other fluids or machinery than intended for at
®
the time of acquisition from Amarillo Gear Company. For other application please contact Ama®
rillo Gear Company
The Gearbox Service Unit System must NOT be used onboard aircrafts.
The Gearbox Service Unit must NOT be used for any liquids used in the direct processing of
foods.


NOTE!
Type of filter element is always selected to match the specific application and oil type.
1.5
Functional description
1.5.1
The Gearbox Service Unit
The main components of the Gearbox Service Unit are:
 A gear pump with electrical motor
 Motor starter
 Filter housing
 Sampling point
 Pressure gauge
 Connections for inlet and outlet
 Drain valve
For specific details please refer fig. 1.1
1.5.2
The Gearbox Service Unit Filter element
 The filter element is the active filter media that maintains the oil by continuously removing particles,
oil degradation products and water from the oil.
1.5.3
Principle of operation
The Gearbox Service Unit takes suction from the oil system, preferably the lowest point of the oil tank.
After passing through the filter element from the outside and inwards, the oil is returned to the system
via the outlet connection of the Gearbox Service Unit.
1.6
Filter performance
To maximise the performance of your Gearbox Service Unit it is important that it is in continuous operation and is serviced by applying both of the following routines
1.6.1
Filter element change based on service time – 12 months
The Gearbox Service Unit Filter element will retain oil degradation products and oxidation by-product
to a level, at which it becomes saturated. It is not possible to indicate this saturation, since it has insignificant influence on the pressure drop across the filter element.
NOTE!
In order to maintain optimal filter performance, the filter element must be changed at
least once per year.
Page 8 of 20
Rev. A 08.07-2010
1.6.2
Filter element change due to high pressure – 1.8 bar
As particles are deposited in and on the Gearbox Service Unit Filter Element and water is absorbed
the flow resistance increases causing increased pressure drop across the filter element. The flow resistance is monitored by the pressure gauge.
If the Gearbox Service Unit Filter System is fitted with a minimess test point, connect pressure gauge
to the minimess test point located on top of the filter housing and read the pressure.
NOTE!
In order to maintain optimal filter performance, the filter element must be changed before the pressure reaches 1.8 bar.
Page 9 of 20
Rev. A 08.07-2010
1.6.3
Technical specifications
Gearbox Service Unit
Motor
Oil pump
Filter element
Filter housing
Type: 1-phase motor with squirrel cage
Voltage: 1x120V
Frequency: 60Hz
-1
Design speed: 1650 min
Protection class:IP55
Gear wheel type PV4
Nominal flow: 300 l/h
Pressure relief valve diff. setting: 2.8bar
Type: Filter element B27/27
Filtration grade: 3µm absolute
Typical pressure drop at 20ºC, new element: <0,3 bar
Max storage time: 12 month, with undamaged package
Material: Cast iron
Surface protection: Norsok
Connections Inlet: ¾”
Outlet: ¾”
Design temperature: 80ºC
Design pressure: 4 bar
Ambient temperature: 40 ºC
Weight: 40 kg
Colour: RAL 6024 (Traffic green)
Table 1.1 Technical data Gearbox Service Unit
Filter unit
Fig. 1.1 Gearbox Service Unit
Page 10 of 20
Rev. A 08.07-2010
2 Installation
2.1
General
The Gearbox Service Unit must be mounted on a correctly dimensioned bracket capable of carrying
the filter system and keeping it in a fixed position under all conditions. The installation must allow for
safe maintenance of the Gearbox Service Unit, e.g. replacement of filter elements.
The Gearbox Service Unit must be connected to the main system by independent suction and return
lines. The filter suction line should be connected to the lowest and most contaminated position, e.g.
the drain plug of the system tank. The filter return line should be led back into the tank close to the
suction pipe of the system pump, and preferably below the oil surface to minimise splashing and reduce oxidation of the oil.
In order to facilitate service of the Gearbox Service Unit, it is advisable to install ball valves on suction
and return lines.
NOTE!
Installation must always be carried out by qualified personnel.
2.2
Taking delivery of a Gearbox Service Unit
2.2.1
Unpacking
Check that the package is undamaged.
2.2.2
Inspection upon receipt
Check that the Gearbox Service Unit and all accessories are undamaged. If damage is found, a damage report should be sent to the company responsible for the shipping (include photographs if relevant). Batch number of the Gearbox Service Unit must be included in the damage report.
2.2.3
Storage until installation
NOTE!
If the Gearbox Service Unit is not to be installed immediately after delivery, the filter
must be stored in its original delivery packaging and in acceptable conditions. A dry
storage room with a relative humidity not exceeding 60% is considered acceptable.
NOTE!
Outdoor storage under cover is accepted only for a short time and requires adequate
protection against all harmful impacts of the climate.
NOTE!
The Gearbox Service Unit must be handled with care, do not drop and protect against
mechanical damage.
NOTE!
Keep the filter element packaging intact until installation!
Page 11 of 20
Rev. A 08.07-2010
2.3
Installation
It is the customer’s responsibility that the Gearbox Service Unit is installed correctly.
Torques
Table 2.1 Torque overview
2.3.1
Piping
Mount the Gearbox Service Unit to the bracket, using class 8.8 bolts or higher. To ensure that the oil
filter system will stay in place even when vibrations occur, apply glue to bolts.
NOTE!
Only use fittings with cylindrical thread in filter or pump.
NOTE!
Never use galvanized or copper fittings/pipes when installing the Gearbox Service Unit.
Inner diameter of connections pipes must be at least 3/8” and as short as possible. In order to avoid
large pressure drop, the inner diameter of the pipes must be increased if the length of pipes is more
than 3 metres.
Suction head must be above -0.5 bar gauge.
Discharge head must be below 0.5 bar.
NOTE!
In order to avoid damage of the pump, make sure all pipes are free of metal particles
and other solvents before connecting the filter system.
Hoses suitable for use with the system fluid can be used instead of pipes. When using hoses for the
installation, they must comply with the same specification as for pipes.
If the Gearbox Service Unit is to be installed in a site where frequent low temperature can influence
fluid characteristics, we recommended insulation of pipes.
2.3.2
Electrical connection
WARNING
ELECTRICAL SHOCK
Make sure that the power supply is safely disconnected before carrying out any wiring
work!
 Work on electric equipment must only be carried out by qualified personnel!
Verify that system voltage matches equipment voltage ratings before connection. Refer to the nameplate on the control panel when sizing power supply wire.
Voltage (AC/DC) tolerance is +/- 5%
Frequency tolerance is +/- 2%
Page 12 of 20
Rev. A 08.07-2010
Connect the electric motor power supply as shown in the wiring diagram in this instruction manual. It is
the customer’s responsibility that the electrical equipment is connected with a cable of the correct dimension and that the electric equipment is properly protected.
WARNING
OVERHEATING OF MOTOR
Overheating of the motor is a potential fire risk.
 Protection of motors against overheating must be provided as either overtemperature protection by connecting thermistors or overload protection by means
of thermal overload relay.
WARNING
ELECTRICAL SHOCK
Different electrical potential between adjacent machinery may cause electrical shock.
 The Gearbox Service Unit must be supplied with power from the same source as
the adjacent machinery or connected by an equipotential bonding wire.
NOTE!
When connected ensure that the motor has the same direction of rotation as the arrow
on the fan cover. Continuous operation with wrong rotation causes no flow in the system and damage shaft seal of pump.
N
P
Z2
U1
Z1
T1
U2
T2
X5
X6
Fig. 2.1 Wire connection for motor
Page 13 of 20
Rev. A 08.07-2010
3 OPERATION
3.1
Starting the filter system
1.
2.
3.
4.
Open inlet and outlet valves (if fitted).
Check that the drain valve is closed
Start the pump
If the filter is equipped with a vent screw on the top of the filter housing,
a. Open vent screw immediately after the pump has been started
b. Close the vent screw as soon as liquid appears
c. Vent the filter again after approximately one hour of operation
5. If the filter is fitted with automatic de-aerator:
a. Observe that the venting process is correctly stopped
6. Check for leaks
Refer fig. 1.1
3.2
Normal operation and service
Pressure drop across the filter element varies with the oil viscosity, but is usually <0.3 bar. However, it
is not unusual for the pressure to be somewhat higher during the first hour of operation until temperature and flow conditions have stabilized.
It is crucial for the Gearbox Service Unit performance that it is in continuous operation, and that the
condition of the filter element is maintained and monitored by applying both of following routines.
3.2.1
Filter change based on service time – 12 months
The Gearbox Service Unit Filter Element will retain oil degradation products and oxidation by-product
to a level at which it becomes saturated. It is not possible to indicate this saturation, since it has insignificant influence on pressure drop across the filter element.
NOTE!
In order to maintain optimal filter performance, the filter element must be changed at
least once per year.
3.2.2
Filter change due to high pressure – 1.8 bar
As particles are deposited in and on the Gearbox Service Unit and water is absorbed the flow resistance increases causing increased pressure drop across the filter element. The flow resistance is
monitored by the pressure gauge.
If the Gearbox Service Unit is fitted with a minimess test point, connect pressure gauge to the minimess test point located on top of the filter housing and read the pressure.
NOTE!
In order to maintain optimal filter performance, the filter element must be changed before the pressure reaches 1.8 bar.
3.3
Stop
Stop the pump and close the inlet and outlet valves (if fitted).
For service or repair, safely disconnect the power supply for the filter system.
Make sure that the power supply cannot be unintended connected.
For additional safety, a pressure relief valve is integrated in the pump to protect the Oil maintenance
unit.
Page 14 of 20
Rev. A 08.07-2010
3.3.1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Replacing the filter element
Stop pump by turning off power. Isolate from external system by closing inlet and outlet valves
Safely disconnect the power supply
Open drain valve and allow filter to drain into a container
When filter is drained, unscrew the top nut and lift off filter cover/filter housing
Unscrew spring nut and remove spring and spring guide
Lift filter element, using the Gearbox Service Unit Filter Element Extractor
Clean all parts and inside of filter base with lint free rags or paper towels
Replace O-rings and seals
Place new filter element in housing
Check that o-ring inside the spring guide is placed correctly in groove
Mount spring guide and spring
NOTE!
Take care not to damage o-ring on thread of stay bolt when mounting spring guide.
12. Mount spring nut and tighten by hand until it touches spring guide disc. Apply an additional 4
turns with a spanner to settle element
13. Check that O-ring at filter base is placed correctly. Mount filter cover/ filter housing
14. Place top nut seal, mount top nut and tighten with a torque wrench to 70 or 90 Nm
15. Put filter back into service by applying the same procedure as described in chapter 3
Page 15 of 20
Rev. A 08.07-2010
Fig. 3.1 Exploded view Gearbox Service Unit
Page 16 of 20
Rev. A 08.07-2010
4 Maintenance
4.1
Preventive Maintenance
The design service life of the Gearbox Service Unit is 20 years.
The following service intervals are based on continuous operation of the filter system.
Service parts and recommended service intervals
Service parts
Frequency of replacement/
design service life
Filter elements
Every year or when pressure
reaches 1.8 bar
Set of O-rings and seals for filter
At every filter element replacehousing
ment
Pump
5 years
Electrical motor
5 years
Table 4.1 Service parts and intervals
Instruction
See Filter Element Replacement Guide
See drawing
See drawing
See spare part list
Check of all electrical connections for tighteness should be done every year including a visual check of
the components.
NOTE!
Depending on operation conditions and used medium pumps with radial shaft seals
may have slight leakage.
NOTE!
Service life can be shortened if exposed to severe vibrations
Page 17 of 20
Rev. A 08.07-2010
4.2
Trouble Shooting
Trouble
Cause
High pressure
Filter clogged by par- Replace filter elements (see "Filter Element Replacement”)
ticles and/or water
Pressure gauge
does not indicate
pressure
Solution
Oil viscosity too high
Check oil temperature.
Check condition of preheater controls, if installed.
Install preheater kit to reduce oil viscosity.
Valve closed in return line
Check main system line
Dimension of
pipes/hoses too
small
Replace with correctly dimensioned pipes/hoses
Filter pump not running
Start pump
Pressure gauge
faulty
Replace pressure gauge
Oil level in system
tank below pump
suction level
Refill oil in system tank and check suction pipe is correctly
fitted (lowest possible point)
O-rings, guides,
spring guides or
spring nut have not
been placed correctly or are damaged
Check O-rings, guides and nuts have been placed correctly
and are not damaged.
Replace damaged parts.
Wrong rotation direc- Change rotation direction of motor
tion of motor
Pump shaft seal
leaking
Bypass valve stuck
open (in pump)
Dismantle and clean bypass valve
Dry running of pump
Replace shaft seal or replace with new pump
Sudden pressure
raise in the oil system
Table 4.2 Trouble shooting
Replace shaft seal or replace with new pump
Page 18 of 20
Rev. A 08.07-2010
Trouble
Cause
Solution
Gearbox Service
Unit stopped
Motor protection
triggered
Reset and restart.
If the motor protection trips again, find cause and remedy
CAUTION
Do not change motor protection relay setting!
Motor protection
triggered
Pressure too high
See under “high pressure”.
No-flow in system
Check that in- and outlet valves are open.
Clean suction strainer. (if fitted)
Pump blocked
Check if pump can be turned by hand:
- If pump cannot be turned by hand, check pump for damage
If necessary replace pump
Motor windings defect
Replace motor
Motor overheated
Motor has been overloaded
Check if pump is blocked
Replace motor
Oil temperature
too high
Temperature setting
too high
Adjust setting to lower temperature.
Oil temperature
too low
Temperature setting
too low
Adjust setting to higher temperature.
Cold oil
Apply heat to the storage tank.
Insulate storage tank and piping.
Install extra preheater kit.
Preheater not turned Turn on preheater. Observe if preheater on lamp is lit
on
If preheater on lamp is not lit, high temperature cut-out has
been activated.
High temperature
cut-out
Reset high temperature cut-out thermostat.
(Press red button on cut-out thermostat inside top of heating
element).
Preheaters fouled
Remove preheater and clean.
Preheater faulty
Replace preheater.
Table 4.2 Trouble shooting
Page 19 of 20
Rev. A 08.07-2010
5 End of life cycle
Introduction
When the Gearbox Service Unit has reached the end of its service life, dismantle and scrap it in accordance with the local regulations.
5.1
CAUTIONS
CAUTION
HAZARDOUS WASTE
The Oil maintenance unit contains oil and sludge which are hazardous to the
environment
→ The drained oil, the used Oil maintenance unit and the used cartridge are
hazardous waste and must be handled in accordance with local regulations
CAUTION
ALLERGIC REACTION
Oil and sludge remains may cause allergic reactions
→ Use protective clothing and gloves when handling
5.2
Material content
Below is a list of material for the individual parts and components of the Oil maintenance unit:
Part
Material
Gearbox Service Unit
Steel and cast iron
Pump
Steel, cast iron and aluminium
Electrical motor
Semi finished steel plate, grey cast iron, steel, cobber and aluminium
Seals
Viton
Pressure gauge
Plastic, steel and silicone
Table 5.1 Material content
Page 20 of 20
Rev. A 08.07-2010